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Arc-Flash Energies at the Individual Motor Control Switchbox

A. Calculation Conditions
The study results indicate that the short circuit contribution from a 150 HP motor M-2
shown in Figure 1 below is insignificant for AF energy at SW BOX2. Therefore, the
individual motor short circuit contribution was not considered in this study.

The individual motor or sub-panel is fed from a MCC, or distribution panel, or bust duct
(busway) through a MCCB or a fused switch. The current ratings of the MCCBs or fuses
were considered between 30 A and 225 A with a typical feeder range of 30 to 300 feet.
The short circuit levels at the MCC, or distribution panel, or bus duct were chosen as 15
kA, 25 kA, and 42 kA. The simplified study system is shown in Figure 1 below.

kV
48
A MCC, or MCC-A

0.
Distribution Panel, M-1 M-2
or Bus Duct with C-H HFD BUSS FRS-R(RK5)
15 kA, or 25 kA, or 225A 225A
Individual
42 kA of Short
Motor
Circuit Current
Protector
CU, 300', [Conduit]

CU, 300', [Conduit]


1-1/C-4/0 AWG

1-1/C-4/0 AWG
Individual
Motor
Feeder
kV

kV
48

48
0.

0.

SW BOX1 SW BOX2
FS-2

Individual Motor
Control Switchbox
M-2

Figure 1 Simplified System for AF Energy Study

B. Conclusion
More than 250 cases were studied. The study results indicate that the arc-flash energies
at the individual motor control switchbox or sub-panel through a individual protestor (a
MCCB or a fused switch) fed from a MCC, or distribution panel, or bus duct with 15 kA,
or 25 kA, or 42 kA of short circuit currents are less than 1.0 Cal/cm2 and require class 0
PPE at a working distance of 18 inches.

The detailed calculation results can be found in the following tables.

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Table 1 Arc-Flash Energies at the Individual Motor Control Switchbox fed from a MCC with 15 kA of Short Circuit Current

Cutler-Hammer HFD Breaker Ampere Rating / Conductor Size


30A / #10 50A / #8 100A / #3 150A / #1/0 200A / #3/0 225A / #4/0
Distance
From Working Incident Required Incident Required Incident Required Incident Required Incident Required Incident Required
MCC Distance Energy Clothing Energy Clothing Energies Clothing Energies Clothing Energies Clothing Energies Clothing
(Feet) (Inches) (Cal/cm2) Class (Cal/cm2 Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class
30 18 0.2 #0 0.3 #0 0.3 #0 0.4 #0 0.4 #0 0.4 #0
24 0.1 #0 0.2 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0.1 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0
50 18 0.2 #0 0.2 #0 0.3 #0 0.3 #0 0.4 #0 0.4 #0
24 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0.1 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0
100 18 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0
24 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0 0.2 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0
150 18 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0 0.3 #0
24 0.1 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0
200 18 0.7 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
24 0.5 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
36 0.3 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0
250 18 1.1 #0 0.6 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
24 0.7 #0 0.4 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
36 0.4 #0 0.2 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0
300 18 1.4 #0 1 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0
24 0.9 #0 0.6 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
36 0.5 #0 0.4 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0

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Table 2 Arc-Flash Energies at the Individual Motor Control Switchbox fed from a MCC with 25 kA of Short Circuit Current

GE TED Breaker Ampere Rating / Conductor Size GE TFJ Breaker Ampere Rating / Conductor Size
30A / #10 50A / #8 100A / #3 150A / #1/0 200A / #3/0 225A / #4/0
Distance
From Working Incident Required Incident Required Incident Required Incident Required Incident Required Incident Required
MCC Distance Energy Clothing Energy Clothing Energies Clothing Energies Clothing Energies Clothing Energies Clothing
(Feet) (Inches) (Cal/cm2) Class (Cal/cm2 Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class
30 18 0.3 #0 0.4 #0 0.6 #0 0.9 #0 0.9 #0 0.9 #0
24 0.2 #0 0.2 #0 0.4 #0 0.6 #0 0.6 #0 0.6 #0
36 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0 0.3 #0
50 18 0.2 #0 0.3 #0 0.5 #0 0.8 #0 0.8 #0 0.9 #0
24 0.1 #0 0.2 #0 0.3 #0 0.5 #0 0.5 #0 0.6 #0
36 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0 0.3 #0
100 18 0.1 #0 0.7 #0 0.4 #0 0.6 #0 0.7 #0 0.7 #0
24 0.1 #0 0.4 #0 0.2 #0 0.4 #0 0.5 #0 0.5 #0
36 0 #0 0.2 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0
150 18 0.4 #0 0.9 #0 0.3 #0 0.5 #0 0.6 #0 0.6 #0
24 0.3 #0 0.6 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0
36 0.2 #0 0.3 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
200 18 0.5 #0 1.1 #0 0.2 #0 0.4 #0 0.5 #0 0.5 #0
24 0.4 #0 0.7 #0 0.1 #0 0.3 #0 0.3 #0 0.4 #0
36 0.2 #0 0.4 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
250 18 0.7 #0 1.3 #0 0.2 #0 0.4 #0 0.4 #0 0.5 #0
24 0.4 #0 0.8 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0
36 0.2 #0 0.5 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
300 18 0.8 #0 1.5 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0
24 0.5 #0 1 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0
36 0.3 #0 0.5 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0

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Table 3 Arc-Flash Energies at the Individual Motor Control Switchbox fed from a MCC with 42 kA of Short Circuit Current

Cutler-Hammer HFD Breaker Ampere Rating / Conductor Size


30A / #10 50A / #8 100A / #3 150A / #1/0 200A / #3/0 225A / #4/0
Distance
From Working Incident Required Incident Required Incident Required Incident Required Incident Required Incident Required
MCC Distance Energy Clothing Energy Clothing Energies Clothing Energies Clothing Energies Clothing Energies Clothing
(Feet) (Inches) (Cal/cm2) Class (Cal/cm2 Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class
30 18 0.2 #0 0.3 #0 0.6 #0 0.7 #0 0.7 #0 0.8 #0
24 0.2 #0 0.2 #0 0.4 #0 0.5 #0 0.5 #0 0.5 #0
36 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
50 18 0.2 #0 0.2 #0 0.5 #0 0.6 #0 0.7 #0 0.7 #0
24 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0 0.5 #0
36 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0 0.3 #0
100 18 0.1 #0 0.1 #0 0.3 #0 0.4 #0 0.5 #0 0.6 #0
24 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0
36 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
150 18 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.5 #0 0.5 #0
24 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
200 18 0.7 #0 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0
24 0.4 #0 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0
36 0.2 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0
250 18 1 #0 0.5 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0
24 0.7 #0 0.3 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0
36 0.4 #0 0.2 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0
300 18 1.4 #0 0.9 #0 0.1 #0 0.2 #0 0.3 #0 0.4 #0
24 0.9 #0 0.6 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
36 0.5 #0 0.3 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0

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Table 4 Arc-Flash Energies at the Individual Motor Control Switchbox fed from a MCC with 15 kA of Short Circuit Current

Bussmann FRS-R (RK-5) Fuse Ampere Ratings / Conductor Size


30A / #10 50A / #8 100A / #3 150A / #1/0 200A / #3/0 225A / #4/0
Distance
From Working Incident Required Incident Required Incident Required Incident Required Incident Required Incident
MCC Distance Energy Clothing Energy Clothing Energies Clothing Energies Clothing Energies Clothing Energies Required
(Feet) (Inches) (Cal/cm2) Class (Cal/cm2 Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Clothing Class
30 18 0.2 #0 0.2 #0 0.3 #0 0.3 #0 0.4 #0 0.5 #0
24 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0.1 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0
50 18 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.4 #0 0.5 #0
24 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0
100 18 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.5 #0
24 0 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
150 18 0 #0 0.1 #0 0.3 #0 0.4 #0 0.5 #0 0.6 #0
24 0 #0 0 #0 0.2 #0 0.2 #0 0.3 #0 0.4 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
200 18 0 #0 0.1 #0 0.4 #0 0.4 #0 0.5 #0 0.6 #0
24 0 #0 0 #0 0.2 #0 0.3 #0 0.3 #0 0.4 #0
36 0 #0 0 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
250 18 0 #0 0.1 #0 0.5 #0 0.5 #0 0.6 #0 0.6 #0
24 0 #0 0.1 #0 0.3 #0 0.3 #0 0.4 #0 0.4 #0
36 0 #0 0 #0 0.2 #0 0.2 #0 0.2 #0 0.2 #0
300 18 0 #0 0.1 #0 0.5 #0 0.5 #0 0.6 #0 0.7 #0
24 0 #0 0.1 #0 0.3 #0 0.3 #0 0.4 #0 0.5 #0
36 0 #0 0 #0 0.2 #0 0.2 #0 0.2 #0 0.3 #0

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Table 5-Arc Flash Energies at the Individual Motor Control Switchbox fed from a MCC with 25 kA of Short Circuit Current

Bussmann FRS-R (RK-5) Fuse Ampere Ratings / Conductor Size


30A / #10 50A / #8 100A / #3 150A / #1/0 200A / #3/0 225A / #4/0
Distance
From Working Incident Required Incident Required Incident Required Incident Required Incident Required Incident
MCC Distance Energy Clothing Energy Clothing Energies Clothing Energies Clothing Energies Clothing Energies Required
(Feet) (Inches) (Cal/cm2) Class (Cal/cm2 Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Clothing Class
30 18 0.2 #0 0.2 #0 0.4 #0 0.4 #0 0.5 #0 0.5 #0
24 0.1 #0 0.2 #0 0.3 #0 0.3 #0 0.3 #0 0.3 #0
36 0.1 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
50 18 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0 0.4 #0
24 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.3 #0 0.3 #0
36 0 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
100 18 0.1 #0 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0
24 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0
150 18 0 #0 0.1 #0 0.3 #0 0.3 #0 0.4 #0 0.5 #0
24 0 #0 0 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0
200 18 0 #0 0.1 #0 0.3 #0 0.4 #0 0.4 #0 0.5 #0
24 0 #0 0 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
250 18 0 #0 0.1 #0 0.4 #0 0.4 #0 0.5 #0 0.6 #0
24 0 #0 0.1 #0 0.3 #0 0.3 #0 0.3 #0 0.4 #0
36 0 #0 0 #0 0.2 #0 0.1 #0 0.2 #0 0.2 #0
300 18 0 #0 0.1 #0 0.5 #0 0.5 #0 0.5 #0 0.6 #0
24 0 #0 0.1 #0 0.3 #0 0.3 #0 0.3 #0 0.4 #0
36 0 #0 0 #0 0.2 #0 0.2 #0 0.2 #0 0.2 #0

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Table 6 Arc-Flash Energies at the Individual Motor Control Switchbox fed from a MCC with 42 kA of Short Circuit Current

Bussmann FRS-R (RK-5) Fuse Ampere Ratings / Conductor Size


30A / #10 50A / #8 100A / #3 150A / #1/0 200A / #3/0 225A / #4/0
Distance
From Working Incident Required Incident Required Incident Required Incident Required Incident Required Incident
MCC Distance Energy Clothing Energy Clothing Energies Clothing Energies Clothing Energies Clothing Energies Required
(Feet) (Inches) (Cal/cm2) Class (Cal/cm2 Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Class (Cal/cm2) Clothing Class
30 18 0.2 #0 0.3 #0 0.5 #0 0.6 #0 0.7 #0 0.7 #0
24 0.1 #0 0.2 #0 0.3 #0 0.4 #0 0.4 #0 0.4 #0
36 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0 0.2 #0
50 18 0.1 #0 0.2 #0 0.4 #0 0.5 #0 0.6 #0 0.6 #0
24 0.1 #0 0.1 #0 0.3 #0 0.3 #0 0.4 #0 0.4 #0
36 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0 0.2 #0
100 18 0.1 #0 0.1 #0 0.2 #0 0.4 #0 0.4 #0 0.5 #0
24 0 #0 0.1 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
150 18 0 #0 0.1 #0 0.3 #0 0.3 #0 0.4 #0 0.4 #0
24 0 #0 0 #0 0.2 #0 0.2 #0 0.2 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.1 #0
200 18 0 #0 0.1 #0 0.3 #0 0.3 #0 0.4 #0 0.5 #0
24 0 #0 0 #0 0.2 #0 0.2 #0 0.3 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.1 #0 0.2 #0
250 18 0 #0 0.1 #0 0.4 #0 0.4 #0 0.4 #0 0.5 #0
24 0 #0 0.1 #0 0.3 #0 0.3 #0 0.3 #0 0.3 #0
36 0 #0 0 #0 0.1 #0 0.1 #0 0.2 #0 0.2 #0
300 18 0 #0 0.1 #0 0.5 #0 0.4 #0 0.5 #0 0.5 #0
24 0 #0 0.1 #0 0.3 #0 0.3 #0 0.3 #0 0.4 #0
36 0 #0 0 #0 0.2 #0 0.2 #0 0.2 #0 0.2 #0

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